Coating material and its application in the coating of sur

ABSTRACT

In a coating material that hardens reactively without solvent evaporation and with an evaporation of maximal 15 mass % water, composed of at least two components, the first component contains a 60-70% mixture of bitumen and water in a quantity of 50 to 100 partial mass %, 0 to 50 partial mass % synthetic latex or natural latex, polyvinyl acetate emulsion, or acrylate emulsion, paraffin emulsion or wax emulsion and 0 to 10 partial mass % viscosity control agent, thixotropic additives and adhesion improving additives and that the second component contains 20 to 50 partial mass % filling material, 40 to 80 partial mass % softening, non-volatile oil and 0 to 10% by weight viscosity control agent, dispersing aids and wetting agents for oily phases and that the first component and the second component are mixed in a ratio of 100:10 up to 50 mass %. The coating material can be used for a moisture insulating coating of surfaces in every alignment and/or for the sealing of joints and gaps. The first and the second component are separately conveyed to a mixer and mixed in it and the mixture of the components is sprayed on the surface by a spray nozzle.

The invention relates to a coating material that hardens reactively without solvent evaporation and with an evaporation of maximal 15 mass % water as well as the use thereof and a method for applying the same to all types of buildings. According to the invention vertical surfaces (like walls, (trapezoid) plates for industrial halls, cladding elements) can be coated as well as horizontal surfaces (like ceilings, flat roofs, floors, parts of bridges and roads), inclined surfaces (like dams, gutters, channels) and the transition parts of different construction sites (like connections of walls with the floor plate).

In structural engineering buildings made of concrete or other building materials as e.g. road asphalt are generally coated in various ways to avoid the penetration of water. Concrete, asphalt and suchlike used as a construction body which is to a large extent rigid, are generally vulnerable to the creation of cracks (subsidence cracks and tension cracks, for static or thermal reasons) or holes or potholes. Such cracks promote the penetration of water. In order to avoid this, permanently plastic or elastic-viscous coatings are applied to the side of the construction body which faces the penetrating water. Buildings composed of other building materials as wood, clinker, clay can be sealed in the same or in a similar way.

According to prior art such sealing coatings are produced n the following different ways:

-   -   a. gluing on or melting on of sheets or foils, e.g. roof sheets,         bitumen sheets, self-adhesive bitumen- or polymer modified         bitumen sheets et al. The application of layers demands         preparatory works like the application of a primer, work on         scaffolding, handling of open flames, cutting and overlapping of         the sheets, etc. If the work has to be carried out outsides, the         wind might significantly complicate it. Passages, corners and         edges significantly complicate working with sheets and foils and         often are weak spots for leakages. The working teams have to be         technically skilled, adequately trained and be good team workers         to carry out impeccable work.     -   b. laying on or spraying on of hot liquid thermoplastic         substances like bitumen, polymer modified bitumen, plastics.         Apart from a very complex heat-spraying technology these works         require dry, warm weather, dry bases and cause high work effort         and involve risks for the construction staff, high energy         consumption, etc.     -   c. laying on or spraying on of substances containing solvents.         During the last years this method was practically no longer         applied or was limited to very small construction sections due         to environmental protection issues (evaporation of solvents         contained in the coating which are harmful to the environment).     -   d. laying on or spraying on of liquids, mainly bitumen         emulsions, polymer modified bitumen emulsions, synthetic         dispersions or natural rubber dispersions. This type of coating         can also be applied to lightly moist bases, although only thin         layers can be applied in one working cycle, as on the one hand         the draining off on horizontal surfaces does not allow thicker         layers and on the other hand water has to evaporate while the         layers are drying. Binder systems generally contain about 30% of         water. Enclosed water leads to bubble formations and sealing         damages. The layers generally contain foam bubbles due to the         foam emulsifiers in the emulsions and consequently not         completely free of imperfections. At least 3 to 4 layers have to         be applied one upon the other and have to be dried thoroughly in         between, which results in a high work effort and expenditure of         time. The temperature of the base has to be high enough to allow         a efficient evaporation of water and a formation of a film         enfolding the erosion particles, which generally means at least         +15° C. If rain falls soon after the coating, the not yet         completely dried layers can be damaged partially or washed away         completely, which leads to further work effort and to highly         disturbing contaminations at the construction side. The result         can also be highly affected by frost, even short night frosts.         Very hot weather (sunny side) often causes the formation of a         skin, thus water remains enclosed in the layer and bubbles might         be formed. In order to avoid these disadvantages, two-component         spraying systems were developed, also spraying a precipitant         (generally on aqueous basis), which quickly leads to a breaking         of the emulsions. Thereby draining and washing off during rain         fall can be avoided to a large extent, but the drying times have         to be respected all the same and the minimum film formation         temperatures are necessary. These coating systems do not qualify         either for the cooler construction season.     -   e. In addition to the application of the sealing binder film, it         is often necessary in construction practice to apply insulating         boards to the building structures and to permanently lute them.         All methods described before require a gluing or doweling of the         insulating boards in further complex work steps. Generally the         latter method provokes mechanical damages to the seals which         leads to a reduction of the leak-tightness, or the insulating         boards enclose water from the gluing dispersions which results         in an insufficient durability.

It is the object of the present invention to find a coating material, a use and a method for applying said coating material, which avoid the disadvantages mentioned above and which can be also used in late fall or winter climate, that means at temperatures close to the freezing point.

The object is solved by a coating material according to one or more of the claims 1 to 6, by a use according to one or more of the claims 7 to 9, as well as by a method according to one or more of the claims 10 to 12.

In contrast to the methods applied so far the coating material according to the invention can be used for the coating of building surfaces at a temperature from +1° C. onward, that means in a late fall or winter climate.

The following characteristics of the application and resulting advantages of the coating material according to the invention compared to prior art can therefore be deduced:

-   -   i. As the reactively hardening coating material for the coating         consists of at least 85 to 100 percent active ingredient, up to         a third of the material to be used can be spared compared to         emulsion systems in order to achieve the desired overall layer         thickness. Furthermore the coating material qualifies as well         for sealing or respectively filling of cracks, joints, gaps and         for creating connections between different building bodies such         as sheets, asphalt, curbstones, et al.     -   ii. The disadvantages caused by the evaporation of water from         the layer and the compliance with the minimum film formation         temperatures are small or completely avoided, the coatings are         fully functional soon after the application (minutes to a few         hours). The coating films are impervious and pressure resistant         to water, as they do not contain any bubbles caused by         emulsifiers.     -   iii. The weather influences are almost uncritical, as the water         dilutability is only of short duration or nonexistent. The         minimum film formation temperature is far below zero ° C.,         however. Therefore the coating material according to the         invention can also be used at temperatures close to zero ° C.         and in conditions of high air humidity, thus in the late fall         and in warm winters in central European climatic zones.     -   iv. The material according to the invention and the method         according to the invention do not require processing         temperatures for the material that might lead to burns and         therefore guarantee a very high occupational security standard         for the executing construction staff.     -   v. The method according to the invention allows the seamless         production of a liquid foil, therefore all complex cutting or         overlapping procedures, necessary if sealing sheets are applied,         can be omitted. Difficult building geometries as edges, corners,         apertures can therefore be sealed against water in a functional         and simple manner.     -   vi. The hardening reaction, that means the transformation from a         consistency, capable of flowing and therefore processable when         cold, corresponding to the consistency of highly fluid bees         honey into a highly compact consistency which prevents the         hardened product from draining off on vertical walls, takes         place in such a short time that layers of a thickness of up to 4         mm can be sprayed on or spread with a float in one single         working cycle.     -   vii. There are so few requirements as far the mixture ratio and         the mixture intensity are concerned that both reactive         components can be conveyed to the mixing spray nozzle by means         of a simple pump system (e.g. gear pumps), can be combined there         to a conjoint material stream and be spun on the base to be         coated. Already during the free flight the viscosity starts to         increase due to the beginning hardening reaction. For         construction works with low material requirements, as for         reparation purpose, the method also qualifies for packaging in         cartouches, for example in 2 component cartouches with an         adapter for a static mixer.     -   viii. Due to the to a large extent possible cold working and         high pumpability of the two reactive components it is, as far as         work procedures are concerned, possible to work with the lowest         possible machine equipment, even in areas that are hard to         access, as excavation pits often are. The material storage         containers, pumps and if necessary a compressed air compressor         can be positioned in far distance to the working surface, in         areas which are easy to access. The materials can be conveyed         for up to 100 meters in thin, unheated tubes so that the staff         only has to handle the simply constructed and light airgun         (weight of a few kg only) with three tubes (compressed air and 2         material components). The construction work can therefore be         executed in a very economical manner.     -   ix. Thanks to the excellent adhesive characteristics of the         coating according to the invention during the hardening process,         insulating boards or thermal blankets of all types, even with         thermal sensitivity or solvent sensitivity like polystyrene foam         boards can be glued together. It is not necessary to flash off         substances under the insulating boards, as the coating hardens         reactively, not by distillation.     -   x. Furthermore the coating according to the invention has         anticorrosive characteristics which opens interesting         application possibilities in particular regarding metal         construction.     -   xi. Compared to pure reactively hardening plastic systems, as         the long known acrylate systems, polyurethane systems or epoxy         resin systems the method according to the invention, based on         bituminous and mineral raw materials, stands out because of its         significantly reduced price level, as well as the enormously         crack bridging, elastic-viscous solid body characteristics.         Furthermore these classical reactive artificial resin systems         generally do not qualify for the application of layers in a         thickness of up to 4 mm in one working cycle, as the hardening         takes too long to be able to prevent the draining off on         vertical surfaces with the low viscosities necessary for cold         working.

For processing temperatures close to 0° C. the coating material according to the invention preferably consists of: Component A: Mixture of bitumen and water, with a preferred ratio of 50-100 m % 60 to 40 up to 70 to 30 Synthetic latex or natural latex, polyvinyl acetate 0-50 m % emulsion or acrylate emulsion or paraffin emulsion or wax emulsion Viscosity control agents, like polyethylene glycols, 0-10 m % ether-alcohols or polyethers or higher boiling hydrocarbons thixotropic additives as fabrics, hollow glass microspheres, inorganic or organic silicon derivatives adhesion improving additives as fatty amines, adhesive resins, waxes Component B: Filling additives as rock meal, talc, cement, lime powder, 20-50 m % gypsum, fly ash cement, scoria deriving from iron or steel production softening non-volatile oil, e.g. an adequate mineral oil, 40-80 m % vegetable oil or a derivative thereof, or a synthetic oil, respectively able to start to dissolve the bitumen viscosity control agent, dispersing aids, wetting agent 0-10 m % for oily phases Component A is mixed in a ratio of 100:10 up to 50 m % with component B and is afterward applied in a regular layer thickness to the base to be coated by means of a scraper, squeegee, float. The mixture and applying can preferably also occur in a two component spray-on-method.

As an application example for construction works at lower temperatures two components are mixed as follows: Component A: mixture of bitumen and water 50 m % synthetic latex or natural latex 48 m % viscosity control agent  2 m % Component B: filling substances as rock meal, talc, cement 50 m % linseed oil, tall oil or wood oil 45 m % viscosity control agent  5 m %

The components were mixed in a ratio of 100:20 and displayed the desired characteristics. 

1. A coating material that hardens reactively without solvent evaporation and with an evaporation of maximal 15 mass % water, composed of at least two components, characterized in that the first component contains a 60-70% mixture of bitumen and water in a quantity of 50 to 100 partial mass %, 0 to 50 partial mass % synthetic latex or natural latex, polyvinyl acetate emulsion, or acrylate emulsion, paraffin emulsion or wax emulsion and 0 to 10 partial mass % viscosity control agent, thixotropic additives and adhesion improving additives and that the second component contains 20 to 50 partial mass % filling material, 40 to 80 partial mass % softening, non-volatile oil and 0 to 10% by weight viscosity control agent, dispersing aids and wetting agents for oily phases and that the first component and the second component are mixed in a ratio of 100:10 up to 50 mass %.
 2. The coating material according to claim 1 characterized in that the softening, non-volatile oil is a mineral oil, a vegetable oil or a derivative thereof or a synthetic oil.
 3. The coating material according to claim 1 characterized in that the filling materials are selected from the group consisting of rock meal, talc, cement, lime powder, gypsum, fly ash cement and scoria deriving from iron or steel production.
 4. The coating material according to claim 1 characterized in that the thixotropic additives are selected from the group consisting of fabrics, hollow glass microspheres, inorganic or organic silicon derivatives.
 5. The coating material according to claim 1 characterized in that the adhesion improving additives are selected from the group consisting of fatty amines, adhesive resins and waxes.
 6. The coating material according to claim 1 characterized in that the viscosity control agents are selected from the group consisting of polyethylene glycols, ether-alcohols, polyethers and higher boiling hydrocarbons.
 7. Use of the coating material according to claim 1 for moisture insulating coating of such surfaces as walls, ceilings, dams, channels, floors, bridges, roads or other traffic ways, metal sheets (e.g. cladding sheets), thermal protection elements or thermal blankets and/or sealing of joints and gaps.
 8. The use according to claim 7 characterized in that the coating material is contemporaneously used as adhesive means for an insulating board that is to be applied to the surfaces.
 9. The use according to claim 7 characterized in that the coating material is also used as an anticorrosive coating.
 10. A method for the application of the coating material to a surface according to claim 1 characterized in that the first and the second component are separately conveyed to a mixer and are mixed in it and that the mixture of the components will be sprayed on the surface by means of a spray nozzle.
 11. The method according to claim 10 characterized in that the mixer is part of the spray nozzle and that the components are mixed in the spray nozzle.
 12. The method according to claim 10 characterized in that the components are taken from cartouches and conveyed to an adapter for a static mixer. 